Method for blast freezing a product

ABSTRACT

A method for freezing a commodity includes a plurality of boxes arranged in two rows with a space formed therebetween. A plenum is formed between the two rows of boxes with the plurality of boxes being positioned side-by-side. Air is pulled through and/or around the plurality of boxes and through ventilation holes in the boxes and/or through spacers positioned underneath adjacent boxes and along a length of the space formed between the two rows. The air may be discharged upwardly, horizontally or downwardly therefrom. In addition, the air may be forced through the plenum, along the length of the space formed between the two rows and through ventilation holes in the boxes and/or through spacers positioned underneath adjacent boxes for evenly freezing a commodity positioned in the boxes.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent application Ser. No. 13/478,203, filed on May 23, 2012, which is a divisional of U.S. patent application Ser. No. 11/336,900, filed on Jan. 23, 2006, which claimed priority to U.S. Provisional Patent Application No. 60/645,027, filed on Jan. 21, 2005, the entire contents of which are incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to a method for blast freezing a commodity such as a food product.

2. Description of Background Art

It is common in the food industry to use a blast freezer to freeze various food products. Normally, a blast freezer requires the use of an expensive specially designed tunnel in which food products are positioned on pallets within the tunnel. The tunnel is a freezer that is maintained at a temperature of approximately −40° Fahrenheit (−40° Celsius). Air is blown or pushed onto the food products disposed in the tunnel to freeze the food products. However, as the cold air is first blown or pushed towards the first pallet of food products to be frozen, the air is warmed by the temperature of the food products so that the second pallet in the row is exposed to a warmer air as compared to the first pallet of food products. This problem is exacerbated as air is blown or pushed towards the third pallet and thereafter the fourth pallet and subsequent pallets. Thus, the food products positioned on the last pallet will be frozen at a different time as compared to food products disposed directly adjacent to the air handler. After the food products are frozen, the food products are transferred to a freezer that is maintained at a temperature of approximately −20° Fahrenheit (−28.88° Celsius) or at a temperature of approximately −10° Fahrenheit (−23.33° Celsius).

SUMMARY AND OBJECTS OF THE INVENTION

It is an object of the present invention to provide a method for treating a commodity, such as blast freezing a food product, by pulling air through and/or around pallets and through ventilation holes in boxes stacked on the pallets.

It is a further object of the present invention to provide a plurality of pallets of the commodity that are formed in two rows with a space formed therebetween. A cover is positioned over the space to form a plenum. An air handler is positioned to pull air from between the plurality of pallets and through the ventilation holes in the boxes stacked on the pallets and along the length of the space formed between the two rows for achieving an even flow of air for treating the commodity positioned on the pallets.

These and other objects of the present invention are achieved by providing a method for treating a commodity, such as blast freezing a food product, that includes positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween. Forming a plenum between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. Pulling air in a temperature range of 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) through the ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom and providing an even flow of air to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows of boxes to evenly freeze a commodity positioned in the boxes.

In an embodiment of the present invention, corrugated material may be positioned underneath and/or between adjacent boxes to provide a ventilation space therebetween.

These and other objects of the present invention are achieved by providing a method to freeze a commodity including steps of providing a first and second box of a commodity being disposed adjacent to each other with a space formed therebetween. Forming a plenum between the first box and said second box to permit a flow of air through the boxes. Pulling air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) through the boxes and along a length of the space formed between the first box and second box and discharging the air therefrom and providing an even flow of air to evenly pull air through the first box and the second box and along the length of the space formed between the first and second boxes to evenly freeze a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to freeze a commodity including the steps of providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. Forming a plenum between the two rows of pallets wherein a flow of air is pulled through the ventilation spacers disposed underneath the boxes on the pallets. Pulling air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) through the ventilation spacer disposed underneath the boxes and along a length of the space formed between the two rows and discharging the air therefrom and providing an even flow of air to evenly pull air through the ventilation spacers and along the length of the space formed between the two rows of pallets to evenly freeze a commodity positioned in the boxes on the pallets.

These and other objects of the present invention are achieved by providing a method to freeze a commodity including positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween. Forming a plenum between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. Forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) along a length of the space formed between the two rows and through the ventilation holes in the boxes and discharging the air therefrom and providing an even flow of air to evenly force air along the length of the space formed between the two rows of boxes and through the ventilation holes in the boxes to evenly freeze a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to freeze a commodity including providing a first and second box of a commodity being disposed adjacent to each other with a space formed therebetween. Forming a plenum between said first box and said second box to permit a flow of air through the boxes. Forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) along a length of the space formed between the first box and second box and through the boxes and discharging the air therefrom and providing an even flow of air to evenly force air along the length of the space between the first and second boxes and through the first box and the second box to evenly freeze a commodity positioned in the boxes.

These and other objects of the present invention are achieved by providing a method to freeze a commodity including providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. Forming a plenum between said two rows of pallets wherein a flow of air is forced through the ventilation spacers disposed underneath the boxes on the pallets. Forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) along a length of the space formed between the two rows and through the ventilation spacer disposed underneath the boxes and discharging the air therefrom and providing an even flow of air to evenly force air along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly freeze a commodity positioned in the boxes on the pallets.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:

FIG. 1 is a side elevational view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets;

FIG. 2 is a top plan view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets;

FIG. 3 is a end view of the pallets with a commodity stacked thereon;

FIG. 4 is a end elevational view of an air handler that is positioned between the two rows of pallets;

FIG. 5 is a side elevational view of the air handler illustrated in FIG. 4;

FIG. 6 is a top plan view of the air handler illustrated in FIG. 4;

FIG. 7 is a side elevational view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets and with the spaces formed between adjacent pallets being covered;

FIG. 8 is a top plan view of a plurality of pallets of a commodity being spaced relative to each other and with an air handler being disposed substantially in a central location relative to the plurality of pallets and the spaces formed between adjacent pallets being covered;

FIG. 9 is an end view illustrating a plurality of boxes that are arranged in rows and stacked with corrugated material being disposed underneath and between adjacent boxes for permitting ventilation by pulling air underneath and between adjacent boxes;

FIG. 10 is a side view illustrating a plurality of boxes that are stacked on each other with corrugated material being disposed underneath and between adjacent boxes for permitting ventilation by pulling air underneath and between adjacent boxes.

FIG. 11 is end view illustrating a plurality of boxes that are arranged in rows and stacked with plastic formed spacer being disposed underneath adjacent boxes for permitting ventilation by pulling air underneath adjacent boxes;

FIG. 12 is an end view illustrating a plurality of boxes that are stacked on each other with wood slat spacers being disposed underneath adjacent boxes for permitting ventilation by pulling air underneath adjacent boxes;

FIG. 13 is a top plan view of a plurality of pallets of a commodity being spaced relative to each other according to a second embodiment with air handlers being directly disposed to be in communication with the plenum; and

FIG. 14 is a side elevational view of a plurality of pallets of a commodity being spaced relative to each other according to the second embodiment wherein the air handlers are directly disposed to be in communication with the plenum.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As illustrated in FIGS. 1-3, an apparatus 10 is provided for treating a commodity, such as blast freezing a food product. A plurality of pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D are provided with the commodity stacked on the pallets and the pallets arranged in two rows I and II with a space S formed therebetween. The term space means that the pallets are substantially equally disposed relative to each other to form a continuous space between the pallets. In addition, the term space means that the pallets may be arranged at an angle with corners of the end pallets engaging each other and the space continuing to enlarge from the end pallets to an air handler 20.

A cover C is positioned to be placed on the space S or at least a portion of the top surface 12 of the commodities for sealing the two rows of pallets along the top surface. In one embodiment, the cover C can also extend along end surfaces 14, 16 for sealing the space S between the two rows of pallets on the end surfaces 14, 16. The cover C may be a flexible tarp for positioning on space S or on the top surface of at least a portion of the commodities that is sucked up tight to make a seal as air is pulled through the space S formed between the pallets and through the ventilation holes in the boxes stacked on the pallets. In another embodiment, the cover C may be a more rigid board material that is positioned on the space S or on a portion of the top surface of the commodities.

As stated above, it is to be understood that the two rows I and II of pallets 1A-5A, 1B-5B and 1C-5C, 1D-5D may be arranged in straight rows as illustrated in FIGS. 1 and 2. In another embodiment, the two rows I and II may be formed at an angle wherein the end pallets of boxes 1A, 1B and 5C, 5D touch each other for closing the rows. This embodiment is contemplated by the claims and is equivalent to positioning the cover C over the ends of the two rows I and II of pallets for sealing the ends.

A plenum P is formed between the two rows I and II of the pallets 1A-5A, 1B-5B and 1C-5C, 1D-5D with the plurality of pallets being spaced apart 11A-14A, 11B-14B, 11C-14C and 11D-14D from adjacent pallets to permit a flow of air therebetween. The boxes of commodities positioned on the pallets include a plurality of ventilation holes H for permitting air to be pulled through the boxes as the commodity is blast frozen.

The air handler 20 is positioned between the two rows I and II of pallets and is spaced along a length thereof. As illustrated in FIGS. 1 and 2, the air handler 20 is disposed at approximately the mid-point of the two rows I and II. In other embodiments of the present invention, two or more air handlers 20 may be positioned along the length of the two rows I and II to ensure a proper flow of air between the pallets. The air handler 20 pulls air from between the plurality of pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along a length of the space S formed between the two rows I and II and discharges the air either upwardly, horizontally or downwardly therefrom. The discharge of air upwardly permits the air that has been warmed by blast freezing a commodity to be discharged towards the ceiling in the room in which the pallets are positioned.

As illustrated in FIGS. 4-6, the air handler 20 includes a housing 22, 24 that is approximately the size of a pallet loaded with boxes of a commodity. At least one fan 26 that is operatively connected to a motor is disposed within the housing for creating an even flow of air that is pulled from between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D and through the holes H in the boxes for evenly treating a commodity positioned in the boxes on the pallets.

As illustrated in FIGS. 5 and 6, two fans 26, 28 may be provided for creating an even flow of air that is pulled between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D and through the ventilation holes H in the boxes for evenly treating a commodity positioned in the boxes on the pallets.

By positioning the air handler 20 between the rows I and II of pallets, an even flow of air is achieved from between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D and through the holes H in the boxes for evenly treating a commodity positioned in the boxes on the pallets.

As illustrated in FIGS. 1, 4 and 5, the cover C or tarps 32, 34 may be secured directly on the air handler 20 for permitting the cover C or tarps 32, 34 to be extended therefrom for covering the space S between the boxes or at least a portion of a top surface 12 of the commodities positioned in the boxes disposed on the pallets. The cover C or tarps 32, 34 may be rolled up for storage by using the handles 33, 35. In one embodiment, the cover C or tarps 32, 34 may also extend along end surfaces 14, 16 for sealing the space S between the two rows of pallets and the end surfaces 14, 16.

The apparatus 10 of the present invention may be used as a blast freezer for freezing the commodity, such as a food product. By placing the pallets of food products in a normal freezer at a temperature in a range of approximately 8 degrees F. to −20° Fahrenheit (−13.33 degrees C. to −28.88° Celsius) and using an air handler 20 an even flow of air is achieved from between adjacent pallets 11A-14A, 11B-14B, 11C-14C and 11D-14D and through the ventilation holes in the boxes stacked on the pallets and along the two rows I and II of the pallets 1A-5A, 1B-5B, 1C-5C and 1D-5D for evenly blast freezing a commodity positioned in the boxes on the pallets. Thereafter the products may be positioned into a freezer that is maintained at approximately −10° Fahrenheit (−23.33° Celsius).

A substantial savings in energy is achieved by using the present invention to blast freeze a product. The expensive, specially designed tunnel that is maintained at a low temperature of approximately −40° Fahrenheit (−40° Celsius) is no longer needed.

The present invention may be used with any number of pallets arranged in straight rows or in rows disposed at an angle relative to each other. The air handler 20 is portable for positioning the air handler 20 in a warehouse, a freezer, or in any environment for permitting the treating of a commodity as the need arises. The present invention is not limited for use in a freezer. The present invention provides for blast freezing for ensuring that a commodity is properly handled depending on the conditions required for the commodity.

The speed of blast freezing permits the present invention to process a commodity very quickly.

The blast freezing of a food product according to the present invention occurs within 36 hours at a temperature of approximately −8° Fahrenheit (−22.22° Celsius). This is to be compared to a conventional tunnel that is used to blast freeze a food product in 72 hours at a temperature of approximately −40° Fahrenheit (−40° Celsius). Again, a substantial saving occurs by reducing the time and the energy needed for blast freezing the food product. Thus, a better turn over occurs to permit additional food products to be blast frozen by using the present invention.

Pulling the air through the pallets makes it possible to form a plenum to block the air flow where needed by using a cover C or tarp that is sucked up tight to make a seal with the space S as compared to providing a rigid structure. By pulling the air through the pallets and through the ventilation holes in the boxes stacked on the pallets the air flow seals the tarps to space S. In another embodiment, the cover C or tarp may be positioned on a portion of the top surface of the boxes wherein the seal with the space S is formed without the need of using a rigid structure.

As illustrated in FIGS. 7 and 8, an apparatus 100 is provided for treating a commodity, such as blast freezing a food product. A plurality of pallets 101A-105A, 101B-105B, 101C-105C and 101D-105D are provided with the commodity stacked on the pallets and the pallets arranged in two rows I and II with a space S formed therebetween. The term space means that the pallets are substantially equally disposed relative to each other to form a continuous space between the pallets. In addition, the term space means that the pallets may be arranged at an angle with corners of the end pallets engaging each other and the space continuing to enlarge from the end pallets to an air handler 20.

A cover C is positioned to be placed on the top of the space S and may be positioned on at least a portion of the top surface 112 of the commodities for sealing the two rows of pallets along the top surface. In one embodiment, the cover C can also extend along end surfaces 114, 116 for sealing the space S between the two rows of pallets along the end surfaces 114, 116. The cover C may be a flexible tarp for positioning on the space S or on the top surface of the commodities that is sucked up tight to make a seal as an air flow is pulled through the ventilation holes H. In another embodiment, the cover C may be a more rigid board material that is positioned on the top surface of the space S or on the commodities.

As stated above, it is to be understood that the two rows I and II of pallets 101A-105A, 101B-105B and 101C-105C, 101D-105D may be arranged in straight rows as illustrated in FIGS. 7 and 8. In another embodiment, the two rows I and II may be formed at an angle wherein the end pallets of boxes 101A, 101B and 105C, 105D touch each other for closing the rows. This embodiment is contemplated by the claims and is equivalent to positioning the cover C over the ends of the two rows I and II of pallets for sealing the ends.

A plenum P is formed between the two rows I and II of the pallets 101A-105A, 101B-105B and 101C-105C, 101D-105D. The plurality of pallets may be spaced apart with covers 111A-114A, 111B-114B, 111C-114C and 111D-114D disposed in the space for blocking the flow of air. The covers 111A-114A, 111B-114B, 111C-114C and 111D-114D may be positioned on the exterior of the two rows I and II of the pallets as illustrated in FIGS. 7 and 8 for sealing the space formed between adjacent pallets. In addition, the covers 111A-114A, 111B-114B, 111C-114C and 111D-114D may be positioned on the interior of the two rows I and II of the pallets for sealing the space formed between adjacent pallets. The covers 111A-114A, 111B-114B, 111C-114C and 111D-114D may be a tarp that is secured to adjacent pallets with Velcro. The space between adjacent pallets may be eliminated if the boxes are stacked on the pallets with the boxes extending to the edge of the pallets so as to permit boxes stacked on adjacent pallets to touch each other. The boxes of commodities positioned on the pallets include a plurality of ventilation holes H for permitting air to be pulled through the boxes as the commodity is blast frozen.

The air handler 200 is positioned between the two rows I and II of pallets and is spaced along a length thereof. As illustrated in FIGS. 7 and 8, the air handler 200 is disposed at approximately the mid-point of the two rows I and II. In other embodiments of the present invention, two or more air handlers 200 may be positioned along the length of the two rows I and II to ensure a proper flow of air through the ventilation holes in the boxes stacked on the pallets. The air handler 200 pulls air from through the ventilation holes in the boxes stacked on the pallets and along a length of the space S formed between the two rows I and II and discharges the air either upwardly, horizontally or downwardly therefrom. The discharged air that has been warmed by blast freezing a commodity may be discharged towards the ceiling and/or horizontally and/or downwardly in the room in which the pallets are positioned.

FIGS. 9 and 10 illustrate another embodiment of the present invention wherein a plurality of boxes 200′ are arranged in rows and stacked with corrugated material 202 being disposed underneath the boxes 200′ and corrugated material 204 being disposed between adjacent boxes 200′ for permitting ventilation by pulling air underneath and between adjacent boxes. The term underneath means that the corrugated material 202 extends between two boxes 200′ stacked in a vertical direction wherein air is pulled between the space formed by the corrugated material 202 over the top of a box 200′ that is positioned below the corrugated material 202 and air is also pulled between the space formed by the corrugated material 202 under the bottom of a box 200′ that is positioned vertically above the lower box 200′ and above the corrugated material 202. The corrugated material 202, 204 may be similar to egg carton separators that are used in stacking eggs in a box. In the present invention, the corrugated material 202, 204 provides an air space for permitting ventilation underneath and between the boxes 200′ to enable air to be pulled therethrough to permit blast freezing of a commodity contained in the boxes 200′.

In the embodiment illustrated in FIGS. 9 and 10, the plurality of boxes 200′ do not include ventilation holes. The boxes 200′ are constructed of cardboard or other material and the boxes 200′ are stacked on each other. The corrugated material 202, 204 that is disposed underneath and between adjacent boxes permits ventilation by enabling air to be pulled underneath and between adjacent boxes.

It is also contemplated by the present invention to permit the corrugated material 202, 204 to be used together with the boxes that do contain ventilation holes as illustrated in FIGS. 1, 3 and 7. In this embodiment, air would be pulled through the ventilation holes in the boxes. In addition, due to the positioning of the corrugated material 202, 204 underneath and between the boxes, air would also be pulled underneath and between adjacent boxes to permit blast freezing of a commodity contained in the boxes 200′.

The configuration of the present invention affords an opportunity to utilize aisle ways in a freezer or to utilize an individual room in a freezer to blast freeze a commodity.

In the embodiment illustrated in FIG. 11 the plurality of boxes 300 do not include ventilation holes. The boxes 300 are constructed of cardboard or other material and the boxes 300 are stacked on each other and positioned on a pallet 310. Plastic formed spacers 302 are disposed underneath adjacent boxes for permitting ventilation by enabling air to be pulled underneath adjacent boxes.

It is also contemplated by the present invention to permit the plastic formed spacers 302 to be used together with the boxes that do contain ventilation holes as illustrated in FIGS. 1, 3 and 7. In this embodiment, air would be pulled through the ventilation holes in the boxes. In addition, due to the positioning of the plastic formed spacers 302 underneath the boxes, air would also be pulled underneath adjacent boxes 300 positioned above the plastic formed spacers 302 and above the boxes 300 positioned below the plastic formed spacers 302 to permit blast freezing of a commodity contained in the boxes 300.

In the embodiment illustrated in FIG. 12 the plurality of boxes 400 do not include ventilation holes. The boxes 400 are constructed of cardboard or other material and the boxes 400 are stacked on each other and positioned on a pallet 410. Wood slat spacers 402 are disposed underneath adjacent boxes for permitting ventilation by enabling air to be pulled underneath adjacent boxes 400 positioned above the wood slat spacers 402 and above the boxes 400 positioned below the wood slat spacers 402.

It is also contemplated by the present invention to permit the wood slat spacers 402 to be used together with the boxes that do contain ventilation holes as illustrated in FIGS. 1, 3 and 7. In this embodiment, air would be pulled through the ventilation holes in the boxes. In addition, due to the positioning of the wood slat spacers 402 underneath the boxes, air would also be pulled underneath adjacent boxes to permit blast freezing of a commodity contained in the boxes 400.

As illustrated in FIGS. 13 and 14 a second embodiment of the present invention is set forth wherein a plurality of pallets 601A-610A and 601B-610B of a commodity are spaced relative to each other with air handlers 600, 602 being directly disposed to be in communication with the plenum P.

As illustrated in FIGS. 13 and 14, an apparatus 500 is provided for treating a commodity, such as blast freezing a food product. The plurality of pallets 601A-610A and 601B-610B are provided with the commodity stacked on the pallets and the pallets arranged in two rows with a space S formed therebetween. The term space means that the pallets are substantially equally disposed relative to each other to form a continuous space between the pallets. In addition, the term space means that the pallets may be arranged at an angle with corners of the end pallets engaging each other and the space continuing to enlarge from the end pallets to each of the air handlers 600, 602.

A cover C is positioned to be placed on at least the top of the space S or on at least a portion of the top surface of the commodities for sealing the two rows of pallets along the top surface. In one embodiment, the cover C can also extend along end surfaces for sealing the two rows of pallets along the space S of the end surfaces. The cover C may be a flexible tarp for positioning on the top surface of the space S or on the top surface of the commodities that is sucked up tight to make a seal as air is pulled through the space S formed between the pallets and through the ventilation holes in the boxes stacked on the pallets. In another embodiment, the cover C may be a more rigid board material that is positioned on space S or on the top surface of the commodities.

As stated above, it is to be understood that the two rows of pallets 601A-610A and 601B-610B may be arranged in straight rows as illustrated in FIG. 13. In another embodiment, the two rows I and II may be formed at an angle wherein the end pallets of boxes 601A, 601B and 610A, 610B touch each other for closing the rows. This embodiment is contemplated by the claims and is equivalent to positioning the cover C over the ends of the two rows of pallets for sealing the ends.

A plenum P is formed between the two rows of the pallets 601A-610A and 601B-610B with the plurality of pallets being spaced apart 601A-610A and 601B-610B from adjacent pallets to permit a flow of air therebetween. The boxes of commodities positioned on the pallets include a plurality of ventilation holes for permitting air to be pulled through the boxes as the commodity is blast frozen.

The air handlers 600, 602 are positioned on top of and between the two rows of pallets to be in communication with the plenum P. The air handlers 600, 602 may be spaced along a length of the plenum P according to the needs of a particular freezing operation. As illustrated in FIGS. 13 and 14, the air handlers 600, 602 are disposed at approximately the one-third point along the two rows to ensure a proper flow of air between the pallets. The air handlers 600, 602 include motors 632, 634, respectively, operatively connected to fans for pulling air from between the plurality of pallets 601A-610A and 601B-610B and along a length of the space S formed between the two rows and for discharging the air either upwardly, horizontally or downwardly therefrom. The discharge of air upwardly permits the air that has been warmed by blast freezing a commodity to be discharged towards the ceiling in the room in which the pallets are positioned.

In another embodiment of the present invention, a method to freeze a commodity includes positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween. Forming a plenum between the two rows of boxes to permit a flow of air through ventilation holes in the boxes. Forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) along a length of the space formed between the two rows and through the ventilation holes in the boxes and discharging the air therefrom and providing an even flow of air to evenly force air along the length of the space formed between the two rows of boxes and through the ventilation holes in the boxes to evenly freeze a commodity positioned in the boxes.

In another embodiment of the present invention, a method to freeze a commodity includes the steps of providing a first and second box of a commodity being disposed adjacent to each other with a space formed therebetween. Forming a plenum between the first box and said second box to permit a flow of air through the boxes. Forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) along a length of the space formed between the first box and second box and through the first and second boxes and discharging the air therefrom and providing an even flow of air to evenly force air along the length of the space formed between the first and second boxes and through the first box and the second box to evenly freeze a commodity positioned in the boxes.

In another embodiment of the present invention, a method to freeze a commodity includes the steps of providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween. Providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween. Forming a plenum between said two rows of pallets wherein a flow of air is forced along the length of a space formed between the two rows of pallets and through the ventilation spacers disposed underneath the boxes on the pallets. Forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) along a length of the space formed between the two rows of pallets and through the ventilation spacer disposed underneath the boxes and discharging the air therefrom and providing an even flow of air to evenly force air along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly freeze a commodity positioned in the boxes on the pallets.

The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. 

1. A method to freeze a commodity comprising the following steps: positioning a plurality of boxes of a commodity arranged in two rows with a space formed therebetween; forming a plenum between said two rows of boxes to permit a flow of air through ventilation holes in the boxes; pulling air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) through the ventilation holes in the boxes and along a length of the space formed between the two rows and discharging the air therefrom; and providing an even flow of air to evenly pull air through the ventilation holes in the boxes and along the length of the space formed between the two rows of boxes to evenly freeze a commodity positioned in the boxes.
 2. The method according to claim 1, wherein said commodity is a food product.
 3. The method according to claim 1, wherein the commodity is a food product and the method is performed in a normal freezer that is maintained at a temperature in a temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.).
 4. The method according to claim 1, wherein the air is pulled from approximately midway between the two rows of boxes for evenly pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 5. The method according to claim 1, and further including at least one air handler having a housing that includes a width that is approximately the size of a width of the two rows of boxes and a width of the plenum between the two rows of boxes of the commodity and at least one fan operatively connected to a motor disposed within the housing for pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 6. The method according to claim 1, and further including the step of providing a sealing cover on top of the space for sealing the space between the two rows of boxes to form the plenum, wherein the boxes are at least one box in width along the predetermined length or height.
 7. The method according to claim 1, and further including the step of providing a cover for covering any space formed between adjacent boxes.
 8. The method according to claim 1, and further including at least one air handler mounted above and in direct communication with the plenum and at least one fan operatively connected to a motor disposed within the at least one air handler for pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 9. The method according to claim 1, and further including two or more air handlers, each air handler being mounted above and in direct communication with the plenum, each air handler being positioned along the rows of boxes and at least one fan being operatively connected to a motor disposed within the two or more air handlers for pulling air through the ventilation holes in the boxes and along the length of the space formed between the two rows.
 10. The method according to claim 6, and further including the step of extending the sealing cover along an end surface of the space for sealing the space between the two rows of boxes to form the plenum.
 11. A method to freeze a commodity comprising the following steps: providing a first box of a commodity; providing a second box of a commodity; providing said first and second boxes being disposed adjacent to each other with a space formed therebetween; forming a plenum between said first box and said second box to permit a flow of air through the boxes; pulling air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) through the boxes and along a length of the space formed between the first box and second box and discharging the air therefrom; and providing an even flow of air to evenly pull air through the first box and the second box and along the length of the space formed between the first and second boxes to evenly freeze a commodity positioned in the boxes.
 12. A method to freeze a commodity comprising the following steps: providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween; forming a plenum between said two rows of pallets wherein a flow of air is pulled through the ventilation spacers disposed underneath the boxes on the pallets; pulling air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88 degrees C.) through the ventilation spacer disposed underneath the boxes and along a length of the space formed between the two rows and discharging the air therefrom; and providing an even flow of air to evenly pull air through the ventilation spacers and along the length of the space formed between the two rows of pallets to evenly freeze a commodity positioned in the boxes on the pallets.
 13. The method according to claim 12, wherein said commodity is a food product.
 14. The method according to claim 12, and further including at least one air handler having a housing that includes a width that is approximately the size of a width of the two rows of pallets and the width of the plenum between the two rows of pallets of the commodity and at least one fan operatively connected to a motor disposed within the housing for pulling air through the ventilation spacers positioned underneath at least adjacent boxes and along the length of the space formed between the two rows.
 15. The method according to claim 12, and further including the step of providing a sealing cover on top of the space for sealing the space between the two rows of pallets to form the plenum.
 16. The method according to claim 12, and further including the step of providing a cover for covering any space formed between adjacent boxes.
 17. The method according to claim 12, and further including at least one air handler mounted above and in direct communication with the plenum and at least one fan operatively connected to a motor disposed within the at least one air handler for pulling air through the ventilation spacers underneath at least adjacent boxes and along the length of the space formed between the two rows.
 18. The method according to claim 12, and further including two or more air handlers, each air handler being mounted above and in direct communication with the plenum, each air handler being positioned along the rows of boxes and at least one fan being operatively connected to a motor disposed within the two or more air handlers for pulling air through the ventilation spacers underneath at least adjacent boxes and along the length of the space formed between the two rows.
 19. The method according to claim 15, and further including the step of extending the sealing cover along an end surface of the space for sealing the space between the two rows of boxes to form the plenum.
 20. The method according to claim 12, wherein said ventilation spacers are constructed of corrugated material.
 21. The method according to claim 12, wherein said ventilation spacers are constructed of wood slats.
 22. The method according to claim 12, wherein said ventilation spacers are constructed of plastic material.
 23. A method to freeze a commodity comprising the following steps: providing a plurality of pallets of a commodity arranged in two rows having a predetermined length or height with a space formed therebetween; providing ventilation spacers underneath at least adjacent boxes positioned on the pallets wherein ventilation is provided therebetween; forming a plenum between said two rows of pallets wherein a flow of air is forced through the ventilation spacers disposed underneath the boxes on the pallets; forcing air in a normal freezer temperature range of approximately 8 degrees F. to −20 degrees F. (−13.33 degrees C. to −28.88degrees C.) along a length of the space formed between the two rows and through the ventilation spacer disposed underneath the boxes and discharging the air therefrom; and providing an even flow of air to evenly force air along the length of the space formed between the two rows of pallets and through the ventilation spacers to evenly freeze a commodity positioned in the boxes on the pallets. 